Simulated pre-folded diaper construction

ABSTRACT

A diaper is disclosed having generally, the rectangular dimension of pre-folded diapers and consisting of a simulated pre-fold multi-ply center panel and two single-ply side panels.

United States Patent Kern [54] SIMULATED PRE-FOLDED DIAPER CONSTRUCTION [72] Inventor: Dale W. Kern, Aiken, S.C.

[73] Assignee: Riegel Textile Corporation, Ware Shoals, S.C.

[22] Filed: Oct. 12, 1970 [21] Appl. No.: 80,047

[52] US. Cl. ..128/284 [51] Int. Cl. [58] Field of Search ..l28/284 [56] References Cited UNITED STATES PATENTS 776,087 11/1904 Robitschek ..128/284 X [451 Nov. 21, 1972 l,8l5,059 7/1951 00111515111 ..l28/284 x 2,715,559 7/1955 Dangel et al ..l28/284 x 2,991,786 7/1961 Sullivan ..l28/284 5,072,124 1/1963 1511118011.... ..128/284 3,150,693 9/1954 Seltzer ..128/284 x Primary Examiner-Charles F. Rosenbaum Attorney-Pennie, Edmonds, Morton, Taylor 8!. Adams [5 7 ABSTRACT A diaper is disclosed having generally, the rectangular dimension of pre-folded diapers and consisting of a simulated pre-fold multi-ply center panel and two single-ply side panels.

1 Claim, 3 praying Figures PATENTEDnnm m2 3. 703, 175

INVENTOR DALE W. KERN ATTORNEYS SIMULATED PRE-FOLDED DIAPER CONSTRUCTION BACKGROUND OF THE INVENTION become commercially important. Perhaps the more common variety is the flat diaper which consists of a single layer of fabric, for example about 27 inches square which will be folded in different ways before apl plication to the infant. Such diapers have been the traditional form for many years and are relatively inexpensive to manufacture. More recently, the pre-folded diaper has found increasing commercial acceptance. Diapers according to this design have several folds to form a center section, stitched permanently together. The overall dimensions of such diapers are typically inches by 21 inches or 12 inches by 16 inches (for new born infants). Pre-folds have the advantage of maintaining a greater quantity of material in the center of the diaper for moisture absorbency; however, because of the additional steps of folding and sewing the center panel, such diapers are relatively expensive to manufacture.

It is the purpose of the present invention to providea unique diaper which is less expensive to manufacture than flat diapers of equivalent weight while still possessin g certain advantages of the pre-folded diaper construction.

SUMMARY OF THE INVENTION In accordance with the present invention, a new diaper is constructed having two single-ply side panels and intermediate the side panels a plural ply center panel, each ply of the center panel consisting of a division of the picks or filling forming the side panels, and in combination with a plurality of warp threads. The advantage to this arrangement is that the center panels are woven integrally with each side panel and at the same speed while the overall size of the diaper can be that of a pre-folded diaper. For a given overall weight, the moisture absorbency capacity of the new diaper is at least as much as for a flat diaper, but the expense of manufacture is considerably less since the total woven area of the new diaper is greatly reduced.

These and other aspects and advantages of the present invention will be explained in the detailed description which follows, with reference to the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is an overall perspective view of the diaper according to the present invention;

FIG. 2 is a cross-section of the diaper of FIG. 1 taken in the direction of arrows 2-2; and

FIG. 3 is a view similar to that of FIG. 2 of a modified form of diaper construction according to the present invention.

BRIEF DESCRIPTION OF A PREFERRED EMBODIMENT Referring to the drawing and initially to FIGS. 1 and 2 thereof, a diaper l0 constructed according to the present invention has been illustrated. The diaper 10 consists of two side panels 11, 12 of single ply construction and a center section 13 having two plies 13a, 13b.

The overall size of the diaper 10 will be typically 15 inches by 21 inches or for a new born infant 12 inches by 16 inches.

It will be seen by reference particularly to FIG. 2, that each of the plies 13a and 13b is formed'integrally with the side panels 11 and 12 by causing in the weaving process a division of the filling or picks 14, 16. This means that where for example the loom has been set to weave 30 picks to the inch for side panels 11 and 12, 4

each of center panels 13a and 13b will have only 15 picks to the inch. At the same time, whereas side panels 11 and 12 may have warp threads 17 in a density relationship of 28 to the inch, with respect to center panels 13a, 13b, the warp threads 18, 19 for each panel may have the same density relationship or be perhaps somewhat less dense in the order of 26 threads to the inch.

In the construction shown, the speed of weaving panels 11 and 12 together with center panels 13a, 13b would be the same as for weaving a single-ply construc tion since weaving speed is determined by shuttle speed, i.e., the number of picks per inch. Therefore, a

two-ply center panel is obtained at the very small increased cost of providing one additional set of warp threads 18 or 19.

Moreover, a diaper of this construction can be made to weigh say 37 grams which is the overall weightof an inexpensive flat diaper approximately 27 inches square. The two-ply center panel construction provides for maximum absorbency in the center where it is most needed and the total capacity to absorb is at least as high as the flat diaper of equivalent weight.

Flat diapers 27 inches square require 729 square inches of weaving surface whereas the new diaper at 15 inches by 21 inches requires less than one half the square area to weave, or more precisely 315 square inches. Since a very considerable cost factor is the weaving area, the diaper of FIGS. 1 and 2 is by a significant percentage less expensive to manufacture than a flat diaper of equivalent weight.

FIG. 3 shows an alternate embodiment which is similar to that of FIGS. 1 and 2 except that a center panel 13' intermediate side panels 11', 12 consists of three plies 13a, 13b and 13c. Each of the plies 13a- 13c will include one-third the total number of picks or fillings per inch as in side panels 11 and 12'; however, the threads in the warp direction may be the same or nearly the same. Greater absorbency can be expected in the embodiment of FIG. 3 due particularly to the increased number of plies and, to the increased amount of material provided by the additional warp threads.

The diaper of the present invention besides being less expensive to manufacture than the most inexpensive flat diaper of equivalent weight, also possesses the advantage of holding its appearance without much crinkling after washing. Furthermore, the durability of the new diaper is very good. Thus, the three major factors in manufacturing a commercially acceptable diaper, namely, low cost, high absorbency and durability have been satisfied.

It will be understood that the foregoing description relates to particular embodiments of the invention and is therefore representative. In order to appreciate fully the scope of the invention reference should be made to the appended claims.

What is claimed is:

a plurality of warp threads, the warp threads of each one of said center layers having approximately the same number and size as the number and size of the warp threads in each side panel.

ii l 

1. A woven diaper comprising two side panels each of single layer construction and a center section consisting of more than one layer wherein each center layer is integrally woven with said side panels, each center layer being formed by a division of the filling threads making up each side panel in combination with a plurality of warp threads, the warp threads of each one of said center layers having approximately the same number and size as the number and size of the warp threads in each side panel. 